Moisture Barrier Device

ABSTRACT

A moisture barrier device and method for providing a moisture barrier around a stub-up protruding through a concrete slab.

This application claims priority to U.S. Provisional Patent Application Ser. No. 61/240,324, filed Sep. 8, 2009, the complete disclosure of which is incorporated herein by reference.

FIELD OF THE INVENTIONS

The inventions relate to a moisture barrier device and method for providing a moisture barrier around a stub-up protruding through a concrete slab.

BACKGROUND

As shown in FIGS. 2A and 2B [Prior Art], building codes across the country for most cast in place concrete slabs 40 require a vapor/moisture barrier sheet 20 be provided between the concrete slabs 40 and the sub grade or existing ground 18. Examples of conventional moisture barrier sheets 20 are plastic sheeting such as commercially available Visqueen or Moisturebloc. The moisture barrier sheet 20 protects the slab 40 from ground moisture that can cause problems with the slab 40 or concrete foundation over time. The moisture barrier sheet 20 is commercially available in rolled up sheets which are applied to the existing ground 18. The typical thickness of concrete slabs 40 used for floors is about 4 to about 6 inches.

Any concrete slab 40 that requires electric, plumbing, central vacuums, or other connections (hereinafter referred to generically as “plumbing”) will have protrusions in the slab 40, otherwise known as “stub-ups” 30, where the plumbing protrudes through the slab 40. These stub-ups 30 penetrate the moisture barrier sheet 20 since the plumbing is run through the existing ground 18 first before application of the moisture barrier sheet 20. Typical plumbing and stub-ups 30 are formed of any suitable pipe, such as PVC, copper, steel, or any other desired material or size as desired for the particular application which provides an open passageway 34.

Current practice to accommodate these stub-ups 30 pertaining to the moisture barrier sheet 20 is cutting of the sheet 20, gathering the sheet 20 around the stub-up, shown at 22, and applying duct tape 24 around the sheet 20 and stub-up 30. This method breaches the seal and provides a poor fix at best, while also being time consuming, costly, and inefficient.

SUMMARY

An objective of the inventions is to provide an improved and more cost effective device and method for providing a moisture barrier around a stub-up protruding through a concrete slab.

These objectives and other objectives are obtained by a moisture barrier device for providing a moisture barrier between ground and a concrete slab having at least one stub-up protruding through the concrete slab, the moisture barrier device comprising:

-   -   a cover sized to surround and cover a stub-up to a height of at         least four inches; and     -   a base connected to the cover, the base having a lap portion         that completely surrounds a bottom portion of the cover, the lap         having a width of at least three inches, the lap is constructed         and arranged to provide a moisture proof seal with a moisture         barrier sheet when a weight of concrete is pressed against the         lap and the moisture barrier sheet, and the moisture barrier         device being formed from a moisture barrier material.

The above objectives and other objectives are also obtained by a method of providing a moisture barrier between ground and a concrete slab having at least one stub-up penetrating the concrete slab, the method comprising:

-   -   applying a moisture barrier device over a stub-up, the moisture         barrier device comprising a base connected to a cover, the base         having a lap that completely surrounds a bottom portion of the         cover, and the moisture barrier device being formed from a         moisture barrier material;     -   applying a moisture barrier sheet over ground and cutting at         least one hole in the moisture barrier sheet so that at least         one stub-up protrudes through the moisture barrier sheet, the         moisture barrier sheet contacting the lap; and     -   pouring concrete over the moisture barrier and the lap up to a         desired height, a weight of the concrete pressing against the         moisture barrier sheet and lap to provide a moisture-proof seal         between a top surface of the lap and the moisture barrier sheet         that completely surrounds the stub-up, the cover surrounding and         covering sides of the stub-up to at least the height of the         concrete so that the moisture barrier device is disposed between         the stub-up and the concrete.

These objectives and other objectives are further obtained by a method of providing a moisture barrier between ground and a concrete slab having at least one stub-up penetrating the concrete slab, the method comprising:

-   -   applying a moisture barrier sheet over ground and cutting at         least one hole in the moisture barrier sheet so that at least         one stub-up protrudes through the moisture barrier sheet;     -   applying a moisture barrier device over the stub-up, the         moisture barrier device comprising a base connected to a cover,         the base having a lap that completely surrounds a bottom portion         of the cover and a bottom surface that contacts the moisture         barrier sheet, and the moisture barrier device being formed from         a moisture barrier material; and     -   pouring concrete over the moisture barrier and lap up to a         desired height, the weight of the concrete pressing against the         lap which presses the bottom surface against the moisture         barrier sheet to provide a moisture-proof seal between the         bottom surface and the moisture barrier sheet that completely         surrounds the stub-up, the cover surrounding and covering sides         of the stub-up to at least the height of the concrete so that         the moisture barrier device is disposed between the stub-up and         the concrete.

The moisture barrier device described herein provides a complete moisture barrier between the concrete and ground, as well as between the stub-up and the concrete.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a top view of a preferred moisture barrier device according to the present invention;

FIG. 1B illustrates a side sectional view of the preferred moisture barrier device shown in FIG. 1A;

FIG. 2A illustrates a prior art moisture barrier sheet and stub-up;

FIG. 2B illustrates a prior art moisture barrier sheet, stub-up and concrete slab;

FIG. 3A illustrates a step in a process of providing a moisture barrier around a stub-up protruding through a concrete slab;

FIG. 3B illustrates a step in a process of providing a moisture barrier around a stub-up protruding through a concrete slab;

FIG. 3C illustrates a step in a process of providing a moisture barrier around a stub-up protruding through a concrete slab;

FIG. 4 illustrates an exemplary alternative structure for the moisture barrier device; and

FIG. 5 illustrates an alternative process of providing a moisture barrier around a stub-up protruding through a concrete slab.

DETAILED DESCRIPTION

The inventions will now be explained with reference to the following non-limiting Figs.

FIGS. 1A and 1B illustrate a preferred moisture barrier device 1 having a base 2 and a cover 4. The base 2 has a portion that protrudes from a bottom portion of the cover 4 that is referred to as a lap 3. The lap 3 completely surrounds the bottom portion of the cover 4, as shown in FIG. 1A. The lap 3 has a bottom surface 16 and a top surface 5. While a square base 2 is shown in FIG. 1A, the base 2 can have any shape, such as a circle, with the proviso that the base 2 provide a lap 3 that completely surrounds the bottom of the cover 4. The lap 3 should have a width 14 sufficient to provide a continuous moisture barrier between either the bottom surface 16 or the top surface 5 and a moisture barrier sheet 20, as shown in FIG. 3C or FIG. 5. Examples of suitable widths 14 are at least 3 inches, preferably from about 4 to about 30 inches, and more preferably about 6 to about 24 inches.

The cover 4 defines an interior space 15. The cover 4 should be sized in height 10 and interior width 12 so that the moisture barrier device 1 fits easily over the stub-up 30 so that the bottom surface 16 contacts the moisture barrier 20 and at least the sides of the stub-up 30 are surrounded and covered up to a height of the concrete 40, as shown in FIG. 3C. The interior space 15 can be easily sized as desired for the particular application. If a cone shape is used, the interior width 12 can be for example from about 4 to about 20 inches, preferably about 6 to about 12 inches, and most preferably about 8 inches, and the height 10 can be for example about 4 to about 30 inches, preferably about 10 to about 26 inches. The top 6 of the preferred cone shape is shown in FIG. 1B.

While a preferred cone shaped cover 4 is shown in FIG. 1B, the cover 4 can be any desired shape, such as shown in FIG. 4. Preferably, the cover 4 is enclosed as shown in FIG. 1B so that when concrete is poured over the cover 4 concrete does not penetrate into the interior space 15. However, if desired, while not preferred, the cover 4 can have an opening as shown in the cut position in FIG. 3C. The cone shaped cover 4 is preferred since the top of the cone can be cut at different positions to provide different size holes to match the diameter of the pipe to be surrounded.

The moisture barrier device 1 is formed of a moisture barrier material that provides a moisture barrier. Examples of suitable materials include metals, composites, and plastics. A preferred example is polyethylene. Most preferably, the moisture barrier device 1 is formed of the same material as the moisture barrier sheet 20.

The lap 3 is constructed and arranged so that when the weight of the concrete 40 is applied to the lap 3 and the moisture barrier sheet 20, the moisture barrier sheet 20 is pressed against the top surface 5 or the bottom surface 16 is pressed against the moisture barrier sheet 20 to provide a moisture proof seal between the lap 3 and the moisture barrier sheet 20 that completely surrounds the stub-up 30.

FIGS. 3A-3C illustrate a preferred method of how the moisture barrier device 1 can be used. First, the plumbing and stub-ups 30 are buried in the existing ground 18. Then the moisture barrier device 1 is then laid over the stub-up 30 so that bottom surface 16 contacts the ground 18 or whatever the sub-layer is. Thus, the term ground includes the existing ground and any grade materials or other materials laid down first before the concrete is poured. The moisture barrier device 1 also surrounds and covers at least the sides of the stub-up 30 to the height the concrete 40 will be poured. Optionally, the sides the moisture barrier device 1 are cinched into the sides of the stub-up using tape, ties, string or any other device as shown at 7. Then a moisture barrier sheet 20 is applied over the existing ground 18, and where the stub-ups 30 are located the moisture barrier sheet 20 is cut to provide and opening for the stub-ups 30.

An alternative less preferred method is shown in FIG. 5, in which a moisture barrier sheet 20 is first applied over the existing ground 18, and where the stub-ups 30 are located the moisture barrier sheet 20 is cut to provide and opening for the stub-ups 30. Then the moisture barrier device 1 is then laid over the stub-up 30 so that bottom surface 16 contacts the moisture barrier sheet 20 surrounding the stub-up 30. The cover 4 surrounds and covers the sides of the stub-up 30 to at least the height the concrete 40 will be poured.

Preferably, the moisture barrier device 1 is constructed and arranged such that the weight of the concrete 40 collapses the cover 4 against the stub up, as shown in FIGS. 3C and 5.

Concrete 40 is then poured over the moisture barrier sheet 20 and the lap 3 to the desired height. The moisture barrier device 1 is disposed between the stub-up 30 and the poured concrete 40 to at least the height of the poured concrete 40, as shown in the FIG. 3C. The weight of the concrete 40 presses against the lap 3 and the moisture barrier sheet 20 to provide a moisture proof seal between the lap 3 and the moisture barrier sheet 20 that completely surrounds the stub-up 30. Once the concrete 40 dries, the top of the moisture barrier device 1, if present, can be cut at 38 to provide an opening for the stub-up 30.

While the claimed invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one of ordinary skill in the art that various changes and modifications can be made to the claimed invention without departing from the spirit and scope thereof. 

1. A method of providing a moisture barrier between ground and a concrete slab having at least one stub-up penetrating the concrete slab, the method comprising: applying a moisture barrier device over a stub-up, the moisture barrier device comprising a base connected to a cover, the base having a lap that completely surrounds a bottom portion of the cover, and the moisture barrier device being formed from a moisture barrier material; applying a moisture barrier sheet over ground and cutting at least one hole in the moisture barrier sheet so that at least one stub-up protrudes through the moisture barrier sheet, the moisture barrier sheet contacting the lap; and pouring concrete over the moisture barrier and the lap up to a desired height, a weight of the concrete pressing against the moisture barrier sheet and lap to provide a moisture-proof seal between a top surface of the lap and the moisture barrier sheet that completely surrounds the stub-up, the cover surrounding and covering sides of the stub-up to at least the height of the concrete so that the moisture barrier device is disposed between the stub-up and the concrete.
 2. The method according to claim 1, wherein the cover completely covers the stub-up to prevent concrete from contacting the stub-up during pouring the concrete.
 3. The method according to claim 2, further comprising cutting a top of the cover off after the concrete dries to expose the stub-up.
 4. The method according to claim 1, further comprising cinching the moisture barrier device to sides of the stub-up.
 5. The method according to claim 1, wherein the moisture barrier device is constructed such that the weight of the concrete collapses the cover against the sides of the stub-up.
 6. The method according to claim 1, wherein the moisture barrier device comprises polyethylene.
 7. The method according to claim 1, wherein the width of the lap is at least 3 inches.
 8. The method according to claim 1, wherein the width of the lap is from about 4 to about 30 inches.
 9. The method according to claim 1, wherein the width of the lap is from about 6 to about 24 inches.
 10. The method according to claim 1, wherein the height of the moisture barrier device is from about 4 to about 30 inches.
 11. A moisture barrier device for providing a moisture barrier between ground and a concrete slab having at least one stub-up protruding through the concrete slab, the moisture barrier device comprising: a cover sized to surround and cover a stub-up to a height of at least four inches; and a base connected to the cover, the base having a lap portion that completely surrounds a bottom portion of the cover, the lap having a width of at least three inches, the lap being constructed and arranged to provide a moisture proof seal with a moisture barrier sheet when a weight of concrete is pressed against the lap and the moisture barrier sheet, and the moisture barrier device being formed from a moisture barrier material.
 12. The moisture barrier device according to claim 11, wherein the cover is in the shape of a cone.
 13. The moisture barrier device according to claim 11, wherein moisture barrier device comprises polyethylene.
 14. The moisture barrier device according to claim 11, wherein the cover is enclosed.
 15. The moisture barrier device according to claim 11, wherein the width of the lap is from about 4 to about 30 inches.
 16. The moisture barrier device according to claim 11, wherein the width of the lap is from about 6 to about 24 inches.
 17. The moisture barrier device according to claim 11, wherein the height of the moisture barrier device is from about 4 to about 30 inches.
 18. A method of providing a moisture barrier between ground and a concrete slab having at least one stub-up penetrating the concrete slab, the method comprising: applying a moisture barrier sheet over ground and cutting at least one hole in the moisture barrier sheet so that at least one stub-up protrudes through the moisture barrier sheet; applying a moisture barrier device over the stub-up, the moisture barrier device comprising a base connected to a cover, the base having a lap that completely surrounds a bottom portion of the cover and a bottom surface that contacts the moisture barrier sheet, and the moisture barrier device being formed from a moisture barrier material; and pouring concrete over the moisture barrier and the lap up to a desired height, a weight of the concrete pressing against the lap which presses the bottom surface against the moisture barrier sheet to provide a moisture-proof seal between the bottom surface and the moisture barrier sheet that completely surrounds the stub-up, the cover surrounding and covering sides of the stub-up to at least the height of the concrete so that the moisture barrier device is disposed between the stub-up and the concrete 